Rolling Matrix for a Powder Coating System for Finishing the Surface of a Product and the Relative Method for Its Realisation

ABSTRACT

The rolling matrix for a powder coating system roller comprises at least one elastic layer presenting a plurality of ridges and depressions adapted to reproduce a decorative pattern on the surface of a product, and an elastic substrate supporting the layer, said substrate having basically the same elastic deformability as the layer in a direction parallel to their lying plane, and elastic deformability higher than that of the layer in the orthogonal direction to their lying plane.

The present invention relates to a rolling matrix for a powder coating system roller, for the surface finishing of a product and the relative method of realisation.

At present, powder coating has a wide range of applications for example in the field of imitation wood surface decoration on metal sections normally destined for the production of door and window frames.

The reproduction of the decorative pattern can be obtained by means of a roller matrix composed of a layer of elastically deformable facing which can be applied to the side surface of a roller and which has on its surface, a plurality of ridges and depressions adapted to reproduce the decorative pattern. The roller matrix is suitably adapted for application on a flat profile, but does not produce very good results on a curved profile because in this case the ridges are locally subjected to differential deformation that do not permit uniform contact with the profile.

Moreover, the roller matrix is generally realised using a die obtained by means of chip removal machining using a cutter. The method for realising the die presents various problems, among which, a lack of clear definition and precision in the execution of the die impression, intrinsic to the type of machining and in particular with the tool employed.

Consequently, very often the reproduction of the decorative pattern does not resemble the original material sufficiently. Furthermore, different dies must be created for each decorative pattern required, and as is known, the realisation of dies produced in this manner is extremely laborious and costly.

The technical task of the present invention is therefore to create a roller matrix for a powder coating system roller for the surface finishing of a product as well as a relative realisation method that eliminates the technical problems described in technical state of the art.

In the context of this technical task, one aim of the invention is to create a roller matrix for a powder coating system roller for the surface finishing of a product as well as a relative realisation method that produces an identical, precise, and high-resolution reproduction of a decorative pattern on the surface of a product.

Another aim of the invention is to create a roller matrix for a powder coating system roller for the surface finishing of a product as well as a relative realisation method that permits the identical precise and high-resolution reproduction of a decorative pattern on both flat as well as curved surfaces of a product.

Another aim of the invention is to create a method of realisation for a roller matrix for a powder coating system roller for the surface decoration of a product that permits the duplication and/or customisation of the roller matrix that is extremely versatile, economical, and that can be mass-produced.

The technical task, as well as this and other aims of the invention is achieved with the realisation of a roller matrix for a powder coating system roller, characterised in that it comprises at least one elastic layer presenting a plurality of ridges and depressions adapted to reproduce a decorative pattern on the surface of a product, and an elastic substrate supporting said layer, said substrate presenting basically the same elastic deformability as said layer in a direction parallel to their lying plane, and elastic deformability higher than that of said layer in orthogonal direction to their lying plane.

The present invention also reveals a method for the realisation of a roller matrix for a powder coating system roller adapted to reproduce a decoration pattern on the surface of a product characterised in that it acquires said decorative pattern in the form of digital data, that it transmits said digital data to an electronic processor, and by means of said electronic processor, it processes said data in a manner to generate a command signal, and by means of said command signal, it can control a laser engraving device on the surface of an elastic layer that comprises said matrix, in a manner to create a plurality of ridges and depressions adapted to reproduce said decorative pattern. Other characteristics of the present invention are defined in the following claims.

Further characteristics and advantages of the invention will result clearer from the description of a preferred, but by no means exclusive embodiment, of a roller matrix for a powder coating system roller for the surface finishing of a product as well as a relative method of realisation, illustrated as an example, but to be by no means considered as limiting, in the appended drawing wherein:

FIG. 1 shows an enlarged view in perspective of an edge of a rolling matrix according to the present finding.

With reference to the mentioned FIGURE, a rolling matrix is shown, generally indicated by the numeral 1, which can be wrapped around the roller in a powder coating system.

The rolling matrix 1 comprises at least one elastic layer 2, having a plurality of ridges 4 and depressions 6 adapted to reproduce the decorative pattern on the surface of a product. Preferably, the elastic layer 2 is composed of a silicone material inert to paints and containing no acetate.

The elastic layer 2 is supported by an elastic substrate 3, having basically the same elastic deformability as layer 2 in a direction parallel to their lying plane, and elastic deformability higher than that of layer 2 in orthogonal direction to their lying plane.

Layer 2 and substrate 3 are united in a homogeneous manner along their contact surface 7, preferably by means of gluing. The substrate 3 has a thickness that is greater than that of layer 2. The rolling matrix 1 also comprises a further stiffening layer 5 united with substrate 3 on the opposite side to elastic layer 2.

Substrate 3 and the stiffening layer 5 are united in a homogeneous manner along their whole contact surface 8, preferably by means of gluing.

The stiffening layer 5 is preferably composed of a sheet of plastic material.

The stiffening layer 5 could also be encased inside substrate 3 instead of united to it.

The substrate 3 has a greater elastic deformability than that of layer 2 in orthogonal direction to their lying plane in such a manner, so that during use, when the rolling matrix 1 is engaged with the product to be finished, it is able to absorb most of the counterthrust exercised by the product. In this manner, the crushing of layer 2 is prevented or at least limited.

As a result, not only is the deformation of the ridges 4 prevented or limited in a manner to avoid distorting the decorative pattern that is being reproduced, but it also preserves the integrity of layer 2.

Instead, substrate 3 basically has the same elastic deformability as layer 2 in a direction parallel to their lying plane so that, during use, when the rolling matrix 1 is engaged with the product to be finished, a uniform contact is ensured between the work surface of layer 2 and the surface of the product to be finished whether the surface is flat or curved or has difference in the surface levels.

In fact, thanks to this characteristic, during the deformation of the rolling matrix 1 parallel to its lying plane, no relative sliding occurs between layer 2 and substrate 3 which, if present, would create interfacing tension between layer 2 and substrate 3 resulting in a distortion of the work surface of layer 2.

Lastly, the thickness of substrate 3 is greater than that of layer 2 in proportion with how deeply layer 2 penetration must be increased according to the difference in the surface levels of the product to be finished.

The realisation of the rolling matrix 1, using an equipment not shown, comprises a stage wherein the decorative pattern data is acquired in the form of digital information, a stage wherein the information is transmitted to an electronic processor, a stage wherein the information is processed by the electronic processor, and wherein a command signal is generated, a control stage with the command signal of a laser device for engraving the surface of the elastic layer 2 in a manner so that it creates the ridges 4 and depressions 6 according to the received information.

Subsequently, onto the elastic layer 2 is applied the substrate 3 and onto substrate 3 is applied the reinforcing layer 5.

In particular, the laser creates a decorative pattern by burning or eating away the silicone coated rubber of elastic layer 2, with a level of precision unobtainable using any other known technique.

The resolution of the laser engraving device is so clear that it permits the creation of a decorative pattern having a number of ridges and depressions per area unit that is certainly far greater than those obtainable till now using any other known technique.

In relation to this aspect, it should be emphasised that FIG. 1 shows an enlargement of matrix 1, since it is possible to reduce the actual spaces between the ridges 4 to only a few millimetres or fractions of a millimetre.

More in particular, the decorative pattern used to finish the surface of a product can be acquired from any source, for example a photograph or some other illustration on a paper support, transformed in digital information legible by the electronic processor, for example, such as a scanner or a similar device.

Naturally the decorative pattern can provide an artificial effect for aluminium profiles, an imitation fabric effect or any other similar effect.

Advantageously, in order to duplicate the elastic layer 2, the engraving device is controlled in a manner so that it realises on the surface of a duplicator layer (not illustrated) a plurality of ridges and depressions representing the decorative pattern in negative mode, then the material that composes the elastic layer is deposited by centrifugal action on the duplicator layer in order to create a duplicate of the elastic layer 2, representing the decorative pattern in positive mode, and lastly, the duplicate is removed from the duplicator layer.

More in particular, the duplicator layer is wrapped around the internal side surface of a hollow cylinder placed in rotation, and the material that forms the layer 2 is fed radially from the axis of the cylinder in such a manner so that through centrifugal action, it is deposited on the duplicator layer in the amount sufficient to form an exact duplicate of layer 2 when removed from the forming layer.

The duplication realised in this manner is extremely easy to use and economical because it does not require, as is the case with traditionally applied duplication techniques, the use of dies obtained through chip removal machining.

Rolling with the rolling matrix according to the present invention can be performed in the following manner.

During the travel wherein the roller follows the product, layer 2 exercises contact pressure against the product surface to be decorated, thus applying a layer of paint from the surface of the ridges 4 and at the same time, paint is accumulated inside the depressions 6.

In this manner the powder coating accumulated in the depressions 6 creates a plurality of lines in relief on the surface to be decorated.

The rolling can be performed by rotation with or without sliding the matrix 1 on the surface of the product.

In the former case the possible grades of shading are improved.

If necessary, rolling can be preceded by a brushing stage. The matrix of the present finding is particularly advantageous because it provides an accurate and precise reproduction of the desired decorative pattern in a simple, economical and highly productive manner.

The rolling matrix and the method for its realisation illustrated in the present invention can be subjected to various changes and modifications while remaining within the context of the present inventive concept, moreover, all details can be replaced by technically equivalent elements. Practically speaking, the materials used, as well as their size, can be of any type according to requirements and state of the art. 

1. Rolling matrix for a roller for a powder coating system characterised in that it comprises at least one elastic layer presenting a plurality of ridges and depressions adapted to reproduce a decorative pattern on the surface of a product, and an elastic support substrate for said layer, said substrate presenting basically the same elastic deformability as said layer in a direction parallel to their lying plane, and elastic deformability higher than that of said layer in the orthogonal direction to their lying plane.
 2. Rolling matrix according to claim 1 characterised in that said substrate has a thickness greater than that of said layer.
 3. Rolling matrix according to one or more of the previous claims characterised in that said layer is composed of a silicone material containing no acetate.
 4. Rolling matrix according to one or more of the previous claims characterised in that said layer and said substrate are homogeneously united along their whole contact surface by means of gluing.
 5. Rolling matrix according to one or more of the previous claims characterised in that said substrate bears, on the opposite side to said layer, a further stiffening layer adapted to conform said matrix to said roller.
 6. Rolling matrix according to one or more of the previous claims characterised in that said further layer is composed of a sheet of plastic material.
 7. Rolling matrix according to one or more of the previous claims characterised in that said stiffening layer and said substrate are homogeneously united along their contact surface by means of gluing.
 8. Rolling matrix according to one or more of the previous claims characterised in that said plurality of ridges and said plurality of depressions are created by means of laser engraving.
 9. Product with powder coating produced by a rolling matrix according to any one of the previous claims.
 10. Method for the realisation of a rolling matrix for a powder coating system, adapted to reproduce a decorative pattern on the surface of a product, characterised in that said decorative pattern is acquired in the form of digital information, that said information is transmitted to an electronic processor, said information being processed by means of said electronic processor in a manner so as to generate a command signal, and by means of said command signal, to control a laser engraving device on said surface of one elastic layer that composes said matrix in a manner to create according to said information, a plurality of ridges and depressions adapted to reproduce said decorative pattern.
 11. Method according to the previous claim, characterised in that an elastic substrate supporting said layer is applied to said elastic layer, said substrate having basically the same elastic deformability as said layer in a direction parallel to their lying plane, and elastic deformability greater than that of said layer, in the orthogonal direction to their lying plane.
 12. Method according to any one of the previous claims, characterised in that said layer and said substrate are glued together along the contact surface.
 13. Method according to any one of the previous claims, characterised in that applied to said substrate, on the opposite side to said layer, is a further stiffening layer adapted to conform said matrix to said roller.
 14. Method according to any one of the previous claims, characterised in that for the duplication of said elastic layer, said laser engraving device is controlled in a manner so that it realises on the surface of a duplicator layer a plurality of ridges and depressions representing said decorative pattern in negative mode, the material of said elastic layer is deposited by means of a centrifugal action on said duplicator layer in order to form a duplicate of said elastic layer representing said decorative pattern in positive mode, and said duplicate is removed from said duplicator layer.
 15. Rolling matrix for a roller for a powder coating system adapted to reproduce a decorative pattern on the surface of a product, and the method for the realisation of said matrix, according to the aforesaid description and claims. 